Solar panel tracker systems and methods
A solar panel tracker system is highly reliable and facilitates installation particularly on terrains that are uneven or sloped. The system includes a frame having legs that are coupled to and support a base for a bushing housing assembly that is designed to rotate one or more photovoltaic (PV) solar power panels. Each of the legs is connected to a telescoping support structure that can be adjusted in a vertical direction to accommodate a desired height above sloping terrain. Each of the legs is connected to its respective telescoping support structure with a coupler passing through a slotted bracket thereby allowing adjustment of the leg in a horizontal direction during installation. In addition, the bushing housing base may be coupled to the frame with one or more U-bolts thereby allowing the bushing housing base and thus the bushing housing assembly to rotate during installation.
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This application claims priority to U.S. Provisional Patent Application No. 62/904,510, entitled “A-Frame Assembly” and filed on Sep. 23, 2019, which is incorporated herein by reference.
RELATED ARTPhotovoltaic (PV) solar panels are used to convert sunlight into electrical energy. One or more such solar panels may be mounted on a solar panel tracker system that holds the solar panels and slowly rotates them over the course of a day so that the panels track the sun. That is, the solar panels are slowly rotated so that the light-receiving surface of each solar panel continues to face the sun as it passes from east to west during the course of a day, thereby helping to maximize the amount of sunlight that is received and converted into electrical energy.
An array of solar panels can be extremely heavy, thereby placing considerable load on the solar panel tracker system on which it is mounted. In addition, the solar panels are often used in harsh, outdoor environments where high winds and weight from snow can induce considerable additional loads on the solar panel tracker system. Thus, solar tracker systems need to be designed to bear significant loads and are often complex and expensive to build and install.
In addition, in some cases, it may be desirable to install solar panel arrays on uneven or sloped terrain, thereby creating further complexities in design and installation. It is generally desirable for the solar panel tracker system to accommodate such terrain while still maintaining sufficient mechanical integrity to support the solar power panels. In addition, it is desirable for the solar panel tracker system to be designed to facilitate installation and reduce the likelihood that the system will be installed incorrectly or in a manner that might compromise the mechanical integrity of the system.
The disclosure can be better understood with reference to the following drawings. The elements of the drawings are not necessarily to scale relative to each other, emphasis instead being placed upon clearly illustrating the principles of the disclosure. Furthermore, like reference numerals designate corresponding parts throughout the several views.
The present disclosure generally pertains to solar panel tracker systems that are highly reliable and facilitate installation particularly on terrains that are uneven or sloped. In some embodiments, a solar panel tracker system includes a frame having a plurality of legs that are coupled to and support a base for a bushing housing assembly that is designed to support and rotate one or more photovoltaic (PV) solar power panels. Each of the legs is connected to a telescoping support structure that can be adjusted in a vertical direction to accommodate a desired height above sloping terrain. In some embodiments, each of the legs is connected to its respective telescoping support structure with a coupler (e.g., a bolt) passing through a slotted bracket thereby allowing adjustment of the leg in a horizontal direction during installation. In addition, the bushing housing base may be coupled to the frame with one or more U-bolts thereby allowing the bushing housing base and thus the bushing housing assembly to rotate. The adjustments permitted by the system help to relieve stresses induced by installation misalignments, thereby reducing the overall loads that must be borne by the system.
At various points along the z-direction, the torque tube 22 is coupled to a respective bushing housing assembly 25 that is mounted on a support frame 33. Each bushing housing assembly 25 has a motor (not specifically shown) that is configured to rotate the torque tube 22 and, thus, the solar power panels 14 mounted on the torque tube 22. As an example, as the sun moves from east to west during the day, the solar power panels 14 may be rotated so that the surface of each panel 14 for receiving sunlight faces the sun (e.g., remains substantially perpendicular to the direction of sunlight), thereby increasing the operational efficiency of the solar power panels 14.
As an example,
In
Note that there are various techniques and configurations that may be used to connect the busing housing base 41 to the A-frame 33. In one embodiment, one or more curved couplers 92, such as U-bolts, are used to make the connection. In
As shown by
As shown by
The length (in the y-direction) of each support structure 114 is preferably adjustable, as will be described in more detail below, although it is possible for the length of any support structure 114 to be fixed in other embodiments. By allowing adjustability in the length of a support structure 114, a height of the support structure 114 above ground may be selected to accommodate a sloping terrain, as shown by
In some embodiments, each coupler 136 comprises a bolt 141, as shown by
Before the nuts 149 are tightened on the bolts 141 during installation, as described above, each bolt 141 is permitted to move along the slot 133 through which it passes. Thus, the end of the leg 71 is permitted to move back and forth along the x-direction until the nuts 149 are tightened. This permits adjustability of the ends of the legs 71 in the x-direction in order to accommodate alignment issues between the A-frame 33 and the busing housing assembly 25 during installation, thereby facilitating installation.
In this regard, during installation, misalignments between the bushing housing assembly 25 and the torque tube 22 or the A-frame 33 can induce shearing stresses and other types of loads for which it is desirable to prevent or at least reduce. In an effort to help accommodate misalignments and alleviate these stresses, the solar panel tracker system 15 may be arranged as shown without tightening the nuts 149 for the bolts 141 passing through the legs 71 and the nuts 94 for the U-bolts 92 passing through the baseplate 52 of the bushing housing base 41. Before the nuts 94, 149 are tightened, the A-frame 33 and support structures 114 may be used to support weight, but adjustability between the bushing housing assembly 25 and the A-frame 33 and between the A-frame 33 and brackets 111 are permitted. Specifically, the bushing housing assembly 25 is secured to the section 74 of the A-frame 33, but the base 41 of the bushing housing assembly 25 is permitted to rotate relative to the A-frame 33. In addition, the legs 71 are secured to the brackets 111, but the ends of the legs 71 are permitted to move in the x-direction relative to the brackets 111.
Once the bushing housing base 41 is appropriately positioned relative to the A-frame 33 to accommodate misalignment issues and thus relieve stress, the nuts 94 may be tightened such that further movement between the base 41 and the A-frame 33 is prevented. Further, once the end of each leg 71 is appropriately positioned relative to its respective bracket 111 to accommodate misalignment issues and thus relieve stress, the nuts 149 may be tightened such that further movement between the leg 71 and its respective bracket 111 is prevented.
Note that there are various techniques and configurations that may be used to permit adjustability in the height of a support structure 114. For illustrative purposes, an exemplary support structure 114 for permitting height adjustments will be described in more detail below. However, it should be emphasized that other configurations of the support structure 114 are possible in other embodiments. Further, it is unnecessary for a support structure 114 to be used on each leg 71 of the A-frame 33. As an example, one leg 71 may be inserted into ground and the other leg 71 may be coupled to an adjustable support structure 114 for adjusting its height to account for sloping terrain. Yet other changes and modifications are possible.
As shown by
The inner member 205 has an end that is connected (e.g., welded) to a bracket 111. In some embodiments, the inner member 205 is a hollow or solid pipe that concentrically fits within the hollow region of the outer member 201. The inner member 205 is preferably moved in the y-direction such that the inner member 205 slides within the outer member 201, thereby changing for overall height of the structure 114 until the bracket 211 is positioned at a desired height. The inner member 205 is then secured to the outer member 201 such that further relative movement between the two members 201, 205 is prevented.
Note that there are a variety of techniques and configurations that may be used to secure the inner member 205 to the outer member 201. In some embodiments, the structure 114 has at least one securing device 221 used to secure the inner member 205 to the outer member 201. In the embodiment depicted by
As shown by
During installation, a support structure 114 for each leg 71 of the A-frame 33 may be inserted into the ground, and the bracket 211 of the support structure 114 may be moved in the y-direction until it is at the desired height for connection to the respective leg 71 of the A-frame 33. At this point, the set screws 221 may be screwed into the outer member 201 of the support structure 114 until they press against and deform the inner member 205, thereby securing the inner member 205 such that movement of the inner member 205 relative to the outer member 201 is prevented. By separately establishing a desired height above ground level for each support structure 114, a slope in the terrain at the location of the A-frame 33 can be accommodated. Further, as noted above, to accommodate misalignments in the tracker system 15 caused by sloping terrain or other factors, the position of the legs 71 of the A-frame relative to the brackets 211 in the x-direction can be adjusted and also the bushing housing base 41 can be rotated relative to the A-frame 33. Once the desired positions are obtained during installation, such positions can be locked so that they are maintained over time during normal operation.
Thus, in various embodiments described above, the process of installing a solar panel tracker system 15 is facilitated despite sloping terrain that otherwise could pose problems and create misalignments that induce considerable stresses. In addition, to the extent that misalignments occur, such misalignments can be corrected by adjusting the positioning of the A-frame 33. Thus, a reliable and robust solar panel tracker system 15 can be installed in relatively difficult environments at relatively low costs compared to other conventional systems and techniques.
Claims
1. A solar panel tracker system, comprising:
- a support frame having at least a first leg and a second leg;
- a bushing housing assembly mounted on the support frame, the bushing housing assembly having a base and coupled to a torque tube on which at least one photovoltaic solar panel is mounted, the bushing housing assembly configured to rotate the torque tube;
- a first support structure having a first end and a second end, the first end of the first support structure coupled to the first leg of the support frame, the first support structure having an outer member and an inner member that is telescoped within the outer member, the first support structure having at least one securing device for securing the inner member such that relative movement between the inner member and the outer member is prevented by the at least one securing device; and
- a first bracket connected to the first end of the first support structure for coupling the first end of the first support structure to the first leg of the support frame, wherein the first bracket has a first elongated slot, and wherein the first bracket is coupled to the first leg by a first coupler passing through the first elongated slot.
2. The system of claim 1, further comprising a second support structure having a first end and a second end, the first end of the second support structure coupled to the second leg of the support frame.
3. The system of claim 2, wherein the second end of the first support structure is inserted into ground, and wherein the second end of the second support structure inserted into ground.
4. The system of claim 1, wherein the at least one securing device comprises a set screw passing through the outer member and pressing against the inner member such that the inner member is deformed by pressure from the set screw.
5. The system of claim 1, further comprising at least one U-bolt coupling the base of the bushing housing assembly to the support frame.
6. The system of claim 1, wherein the first coupler comprises a bolt.
7. The system of claim 1, further comprising:
- a second support structure having a first end and a second end, the first end of the second support structure coupled to the second leg of the support frame; and
- a second bracket connected to the first end of the second support structure for coupling the first end of the second support structure to the second leg of the support frame, wherein the second bracket has a second elongated slot, and wherein the second bracket is coupled to the second leg by a second coupler passing through the second elongated slot.
8. The system of claim 1, wherein the first end of the first support structure is tapered.
9. The system of claim 8, wherein the first end of the first support structure is threaded.
10. A method of installing a solar panel tracker system, comprising: mounting a bushing housing assembly on a support frame having at least a first let and a second leg;
- coupling the bushing housing assembly to a torque tube for enabling the bushing housing assembly to rotate the toque tube and at least one photovoltaic solar panel coupled to the torque tube;
- coupling a first end of a first support structure to the first leg of the support frame, the first support structure having an inner member telescoped within an outer member;
- moving the inner member within the outer member thereby adjusting an overall length of the first support structure;
- securing the inner member to the outer member with at least one securing device thereby preventing further movement of the inner member relative to the outer member; and
- coupling, with a first bracket, the first end of the first support structure to the first leg of the support frame, wherein the first bracket is connected to the first end of the first support structure, wherein the first bracket has a first elongated slot, and wherein the coupling the first end of the first support structure to the first leg of the support frame comprises passing a coupler through the first elongated slot.
11. The method of claim 10, further comprising coupling a first end of a second support structure to the second leg of the support frame.
12. The method of claim 11, further comprising:
- inserting a second end of the first support structure into ground; and
- inserting a second end of the second support structure into ground.
13. The method of claim 10, wherein the at least one securing device comprises a set screw, wherein the securing comprises passing the set screw through the outer member such that the set screw presses against and deforms the inner member.
14. The method of claim 10, wherein the mounting comprises coupling the base of the bushing housing assembly to the support frame with at least one U-bolt.
15. The method of claim 10, wherein the first coupler comprises a bolt.
16. The method of claim 10, further comprising coupling, with a second bracket, a first end of a second support structure to the second leg of the support frame, wherein the second bracket is connected to the first end of the second support structure, wherein the second support structure has an inner member telescoped within an outer member, wherein the second bracket has a second elongated slot, and wherein the coupling the first end of the second support structure to the second leg of the support frame comprises passing a second coupler through the second elongated slot.
17. The method of claim 10, wherein the first end of the first support structure is tapered.
18. The method of claim 17, wherein the first end of the first support structure is threaded.
19. The method of claim 14, wherein the coupling the base of the bushing housing assembly to the support frame is performed such that the U-bolt passes around the support frame and through the base of the bushing housing assembly.
20. The system of claim 5, wherein the U-bolt passes around the support frame and through the base of the bushing housing assembly.
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Type: Grant
Filed: Sep 23, 2020
Date of Patent: Sep 10, 2024
Assignee: Terrasmart, Inc. (Buffalo, NY)
Inventors: Jason Tankersley (Sandia Park, NM), Toby Holden (Fort Myers, FL), Kevin Conner (Estero, FL)
Primary Examiner: Mayla Gonzalez Ramos
Application Number: 17/030,241